Contingency Plan Rev. Date : 17.12.

2017
Document Revision NO.: 02 Rev. date: 07.06.2018 Review Frequency : 1 Year Financial Year: 2018 - 2019

Description of issue /
Sr. No. Details Effect of Issue Contingency Plan Validation Date Responsibility Reference Documents
Situation

Loss of Production Weekly Checking of

Utility Interruption Standby Power Supply through D.G Set to critical machines
1 Power Not Available Changes of Premium Freight both DG Set for HOD - Maintenance Register for DG set inspection
Electricity of shop floor.
shipment to customer proper functioning.

Loss of Production
Changes of Premium Freight 1) Ensure Min. stock of diesel - 500 liters Weekly Checking of
Utility Interruption HOD - Stores for diesel stock SAP system
2 D.G.Set Failure shipment to customer 2) Preventive maintenance plan for diesel generators. both DG Set for
Electricity HOD - Maintenance for PM. PM Plan
Chances of customer line 3) Approved service provider for DG set maintenance. proper functioning.
stoppages

Compressed air
1) One additional spare compressor available. HOD - Maintenance
switch over daily

2) Min. - Max. spare list maintained for air compressor Monthly spare review HOD - Maintenance
Loss of Production
Utility Interruption
3 Air Compressor Failure Changes of Premium Freight 3) Service provider available for breakdown/preventive
Air Annual Service Plan HOD - Maintenance
shipment to customer service support. List of service provider maintained.
4) External service provider available up on emergency for
Planned by
rental compressor supply. List of service provider HOD - Maintenance
14.08.2018
maintained.

1) Manual welding machines are available. Total 3

machines available which can take load of robo welding Not required HOD - Maintenance
machines.

Loss of Production
Key Equipment Robo Welding Machine 2) Min. - Max. spare list maintained for robo welding
4 Changes of Premium Freight Monthly spare review HOD - Stores
Failure (RB-2,Cover Shop) machine.
shipment to customer

3) AMC is given to the machine manufacturer which AMC and Service

HOD - Maintenance
includes Breakdown visits as well as planned service visits. Calendar

1) Min. - Max. spare list maintained for Ipsen Furnace. Monthly spare review HOD - Stores

Loss of Production 2) Additional two furnaces are available so critical parts can
Key Equipment Apr-18 HOD- HT
5 Ipsen Furnace Breakdown Changes of Premium Freight be produced to feed assembly line.
Failure
shipment to customer
3) Preventive maintenance plan and monitoring Monthly review HOD - Maintenance

4) Alternate supplier is developed, which can provide job

May-18 HOD - HT
work.S.N.Mettalurgical Services.

1) Min. - Max. spare list maintained for CNC Balancing

Monthly spare review HOD - Stores
machine.
Loss of Production
Key Equipment CNC Balancing Machine
6 Changes of Premium Freight 2) Preventive maintenance plan and monitoring As per plan HOD - Maintenance
Failure Breakdown
shipment to customer
3) Manual balancing machine to be used in case of
Apr-18 HOD - Assembly
breakdown.
 1) Min. - Max. spare list maintained for 1000 Ton press
Monthly spare review HOD - Stores
machine.
Loss of Production
Key Equipment 1000 T machine
7 Changes of Premium Freight 2) Preventive maintenance plan and monitoring As per plan HOD - Maintenance
Failure breakdown
shipment to customer
3) Alternate supplier is to be developed, which can provide
Oct-18 HOD - Press Shop
job work.
1) Min. - Max. spare list maintained for robo laser welding
Monthly spare review HOD - Stores
machine.
Loss of Production
Key Equipment Robo Laser Welding 2) Preventive maintenance plan and monitoring As per plan HOD - Maintenance
8 Changes of Premium Freight
Failure machine breakdown
shipment to customer
3) Annual servicing by machine manufacturer. As per AMC calendar HOD - Maintenance

1) Min. - Max. spare list maintained for Dyno test machine. Monthly spare review HOD - Stores

Delay in Customer validation

Key Equipment Dyno Test machine 2) Preventive maintenance plan and monitoring As per plan HOD - Maintenance
9 timeline
Failure Breakdown
NPD timeline affected
3) Alternate testing service provider available for test
As per requirement HOD - R&D
service support.

1) Min. - Max. spare list maintained for Coil Feeder

Monthly spare review HOD - Stores
Machine.
Loss of Production
Key Equipment Coil Feeder Press
10 Changes of Premium Freight 2) Preventive maintenance plan and monitoring As per plan HOD - Maintenance
Failure Machine Breakdown
shipment to customer
3) In case of urgency coil feeder can be attached to another HOD - Maintenance / HOD -
Oct-18
machine. Press Shop

1) Min. - Max. spare list maintained for Dyno test machine. Monthly spare review HOD - Stores

Delay in tool development time

Key Equipment
11 Wire Cut Machine line 2) Preventive maintenance plan and monitoring As per plan HOD - Maintenance
Failure
NPD timeline affected
3) Servicing and repair of wire cut machine by service
As per AMC calendar HOD - Maintenance
provider

1) More than one labor supplier.

Man power not available / Loss of Production
2) Monthly labor demand and supply monitoring. As per monthly
12 Labor Shortages marriage season / festival Changes of Premium Freight HOD - HR
2) In case of emergency labor can be taken from other demand
season shipment to customer
Setco plant.

More Evacuation time can lead 1) Mock drills for creating awareness.
Mock drills as per
13 Fire Sudden fire in plant area to injury or fatality to 2) Fire extinguishers placed in all areas. HOD - HR Records for Mock drills.
Mock drill plan
employees 3) List of trained employees displayed at shop floor.

1) Monthly schedule and delivery monitoring. Supplier

Loss of Production
Shortage in material performance monitoring, supplier audit system in place.
Changes of Premium Freight Monthly Monitoring HOD - SCM
supply from supplier 2) Alternate supplier development where single source
Interruption from shipment to customer
supplier are available.
externally provided
14
products and
processes Increase in rejection 1) Supplier performance monitoring and audit system.
Quality Issues in material
Chances of customer 2) Alternate source development plan for suppliers having Monthly Monitoring HOD - SCM
supplied
complaint regular quality issues.
 More Evacuation time can lead
Natural Disasters like 1) Proper lay out with emergency exits.
15 Natural Disasters to injury or fatality to As per Mock drill plan HOD - HR Records for Mock drills.
Flood / earth quake 2) Mock drills for creating awareness.
employees

MDT Signoff:

HOD - MAINT. HOD - HR HOD - SCM HOD - R&D HOD - ME HOD - PRESS SHOP HOD - MACHINE SHOP HOD - HT HOD - DIAPHRAGM HOD - ASSEMBLY